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Installation and OperatingMan ual Solitel Vibrating Ro d Level Swi tch
Read thisMan ualBefore Installing T his ma nual provides information on the Solitel Vibrating Ro d Level Switch. It is importantthat all instructionsareread carefullyand followed in sequence. Detailed instructions are included in the Complete Installation section ofthism anual. ConventionsUsed in thisMa nual Certainconventions areused in thism anualto convey specifictypes ofinformation.Generaltechnicalmaterial, support data, and safetyinformation are presented in narrative form. The followingstyles areused for notes, cautions, and warnings. No tes Notescontain information thataugm entsor clarifies an operating step. No tesdo not normallycontain actions. They follow the proceduralsteps to wh ich they refer. C autions Ca utionsalertthe techniciantospecialconditionsthat could injurepersonnel,dam age equipment,or reduce a comp onent’sme chanicalintegrity. Cau tions arealso usedto alertthetechnicianto unsafe practicesor the need for specialprotective equipmen t or specific m aterials.In thismanual, a caution box indicatesa potentiallyhazardous situation wh ich, ifnot avoided, m ay resultinminorormo derate injury. Warnings W arnings identifypotentiallydangerous situations or serioushazards.In thism anual,a w arningindicatesan imminently hazardoussituationw hich, ifnotavoided, could resultin serious injuryordeath. SafetyMe ssages The Solitelsystem isratedby theIEC foruse inCategory II, Pollution D egree 2 installations. Follow all standard industryproceduresforservicingelectricaland com puter equipment wh en working with or around high voltage. Always shut offthe power supply before touching any compon ents.Although highvoltageisnotpresentinthis system, itm ay be presentinothersystems. Electrical components are sensitive to electrostatic discharge. T oprevent equipment dam age, observesafety procedures wh en w orking with electrostatic sensitive compon ents. This device complieswith Part15 of the FCC rules. Operation issubjecttothefollowingtwo conditions:(1) This devicem ay not cause harmfulinterference, and (2) Thisdevice m ustacceptany interference received,includ - ing interferencethatm ay causeundesirableoperation. Low Voltage Directive For use in CategoryIIinstallations.Ifequipment isused in a man ner not specified by m anufacturer, protection provided by equipmentmay be impaired. W AR N ING ! Explosion hazard. D o not connect or disconnectequipmentunlesspower hasbeen sw itched off orthe area isknow n to be non-hazardous. NoticeofC opyrightand Limitations Copy right© 2009 M agnetrolInternational Magn etrol reservesthe right to m ake changes to the product described in thism anual at any time w ithout notice. M agnetrolm akesno warranty with respectto the accuracy ofthe inform ation inthism anual. Wa rranty AllMagne trolelectronicleveland flow controlsare war - ranted freeofdefectsinm aterialsorw orkman shipforone fullyearfrom the date oforiginalfactoryshipment. If returned within the w arranty period; and, upon factoryinspectionofthe control,the cause ofthe claimis determ ined to be covered under the w arranty;then, Magn etrolw illrepairor replacethe controlatno costto the purchaser(orow ner)otherthan transportation. Magn etrol shallnot be liablefor misapplication, labor claims,directorconsequentialdamage orexpensearising from the installation or use of equipment. T here areno other warranties expressed or implied, except specialw ritten warrantiescoveringsom e M agnetrolprod - ucts. Qu alityAssurance T he quality assurance system in place at Magnetrol guarantees the highest levelof qualitythroughou t the compa ny. M agnetroliscommitt ed to providing full custom er satisfaction bo th in qu ality products and qualityservice. Magne trol’squalityassurance system isregistered to ISO 9001 affirm ing its com m itm entto know n international quality standa rds providing the strongestassurance ofproduct/service qualityavailable.
1.0 Introduction
The SolitelVibrating R od LevelSw itch providesreliable leveldetection ofbulksolidsand pow ders. T hiscompact, integralswitchissuitableforhighorlow leveldetection inhoppersand silos.Itmay alsobe usedforplugged chutedetection. The rugged, single-piece probe issuitableforuseina variety ofpowd ersorgranularm aterialsw ith a minimum bulkdensityoflessthanone pound percubic foot.
1.1 PrincipleofO peration
T he Solitelrod vibratesata 35 0 Hz frequency. Wh en media ma kescontactw iththe rod,the vibration isdam p - ened. T he attenuation ofthe vibrationisdetected by the integralmoun telectronics,changing the statusofthe relay.
2.0 Installation
2.1 Unpacking
Un packtheinstrumentcarefully. M akesureallcompo - nentshavebeen removedfrom the packing m aterial. Inspectallcomp onentsfordamage, and reportany concealed damage to thecarrierwithin24 hours. Che ck the contentsofthe carton, making sureitagrees with the packing slip and the purchaseorder.Verifythat them odelnum berimp rinted on the nameplatematches thenum beron thepacking slip and thepurchaseorder. R eportany discrepanciestothe factory. Chec k and record theserialnumbe rforfuture reference w hen ordering parts. SerialNumber
2.2 M ounting
Priorto installation, itisrecom men ded thattheunitbe calibrated using a sampleofthe m edia tobe me asured. Refer toCa libration, Section 2.5. IMPO RT A NT: Hand letheinstrumentwith greatcare, especiallytheprobe. An y imp acton the probe can damage thevibration system . 356-601 SolitelVibratingRod LevelSwitch Figure1
The Solitelswitch ismo unted to the vesselusing a 11⁄2" NP T threaded connection.
- Ensure thatthetip oftheprobe islocated atthe desired switching pointgiving consideration to theslope angleof thematerial.
- T he switch m ay be installedverticallyorhorizontally (ata dow nward angle)asshow n in Figure 1 on page3.
- A void mo unting the sensorin a recesswherebuild-up coulddamp en thevibration. See Figure2.
- D o notcutorbend thevibrating rod. IMPO RT ANT :A deflection plateisrequired wh en the probe isexposedto fallingma terial,collapsed arch, or,inthe caseofa low levelswitch,when the drag forceofthe em pty - ingm aterialexceedthe specifications. T he deflectorcan be a baffle plate orangle iron(1 1⁄2" × 11⁄2" × 1⁄8 ")located 4 to 6 inchesabovetherod. See Figure3. Obs ervethe specificationsforbending force(F), torque(M ),and pullforce(F)asindicated below : See Figure 4. Standard: F = 100 pounds(445 N) M = 63 footpounds(85 Nm) Extended Rigid: M = 63 footpounds(85 Nm) Extended F lexible: F = 10,000 pounds(45 kN) When using an extended lengthversion forlow level alarm, mo untthe probe abovethe outletofthevesselto avoidthe probe beingdraggedalong by theoutflowing material.
2.3 ElectrostaticDischarge (ESD)
Magnetrol’selectronicinstrum entsare man ufactured to thehighestqualitystandards.T hese instrum entsutilize electroniccomp onentsw hich may be damaged by static electricity presentinm ostwo rkenvironme nts.Th e following stepsare recom men ded to reducethe riskof com ponentfailure due to electrostatic discharge: 1. Shipand store circuitboardsinanti-static bags. Ifan anti-staticbag isnotavailable,w rapboardin aluminum foil.D o notplaceboardson foam packing m aterials. 4 56-601 SolitelVibratingRod LevelSwitch VXH VXR VXK F M F M Figure 4 Figure2 Figure 3
- U sea grounding w riststrapwhen installing and rem oving circuitboards. A grounded w orkstationis also recom me nded. 3. Hand leprinted circuitboardsonlyby the edges.D o not touch com ponentsorconnectorpins. 4. Ensure thatallelectricalconnectionsare com pletelymad e and none are partialorfloating. Gr ound allequipmentto a good earth ground w iring.
2.4 Wiring
M anuallyposition the housing inthe correctdirection to allow foreasywiring. Th e housingcan rotate one fullturn. 1. Make surethe pow ersupplyisturned off. 2. Un screw and rem ovehousing cover. 3. Co nnectpowerleadstothe properterminals. T osimplify wiring, theterminalstripsmay be remo ved from the m oduleby liftingthe frontedge ofthe term inalblock. R efertoF igure 5. a. 120 VAC – Co nnectthe “hot” w ireto term inalmarked L1 and the“neutral” to term inalL2/N. T here isno con - nection to thecenterterminal. b. 240 VAC – Co nnectone w ireto term inalL1 and the otherw ire toterminalL2/N. Thereisno connection to thecenterterminal. c. 24 V DC – Con nectwirestoterminals(+) and (-).T here isno connection to thecenterterminal. 4. T o ensure optimum noise im mun ity, attach the ground wireto thegreen grounding screw inside thehousing base. Cau tion: On 24 VD C units,thenegativeterminalofthepowe r supply is isolated from ground and properearthgrounding ofthepow ersupply shield w ireisnecessaryfornoise imm unity. 5. Co nnectrelayterminals. R eferto Figure 6. 6. Setthe fail-safe jumperasdescribed inthe tableon page 6 . Fo ralarmapplications, itisrecom me nded thatthe de-energized statusofthe relaybe used asthealarm status. Thisallowsdetection ofpow erfailure asan alarm status. 7. Wi ring iscom plete.Replace the housing cover. 8. A pplypowertotheunit. 556-601 SolitelVibratingRod LevelSwitch Figure6 L1(+)No Connection L2/N(-) Power LED Failsafejumper Sensitivity adjustment NO CO NC Relay Figure5
2.5 Calibration
Ensure thatthe fail-safe jump erisinstalled intheproper position asdescribed inTable1. The LED w illshow red w hen inalarmcondition and greenwhen in normal condition. T estthe operation ofthe switch by holding, and then releasingthevibrating rod;the LED will change color . The sensitivity oftheswitch can be changed using the densityadjustme ntscrew. Not e thatthisadjustme ntscrew has270degreesofrotation. D o notrotate pastthe stops. NO TE: Ifthe adjustmentistoo sensitive,theswitch m ay detect even slightresidue ofm aterialratherthanlevel. Priorto installation, itisrecom men ded thattheunitbe calibrated using a sampleofthe m edia tobe m easured. 6 56-601 SolitelVibratingRod LevelSwitch Powe r Ma terialLevel Fail-SafeJum per LED Color RelayCoil Relay Terminal NO to CO NC to CO 6–7 7–8 On H igh A position Green De-energized Open Closed B position Red Energized Closed Op en On Low A position Red Energized Closed Op en B position Green De-energized Open Closed Fail H igh/Low A/B De-energized Open Closed
3.0 Reference Information
3.1 Troubleshooting
Solitelisa simpleand reliabledevice. H ow ever,caremu st be takentoavoidimp acting ordamaging the vibrating probe. In the eventtheSolitelstopsvibrating, thefollowingpro - cedurew illidentifyifthe problem isw ith the electronic mo duleorw iththesensor: D isconnectthe wiresgoing to thesensor. (T erminals3, 4, and 5). T he following givesthe expected voltage range betw een thesensors. Ifthesevoltagereadingsare notobtained, the electronics are defectiveand need to be replaced. Ifthesevoltagesare me asured, the problem isw iththe sensor. N OTE: The probe and electronics must be ma tched to ensure proper operation.U se the follow ing procedure to m atch theelectronics and thevibrating probe: 1. Co nnectthe wiresfrom the sensorto terminals3, 4, 5. There willbe two wiresofthe sam e colorand one wireof differentcolor.The two sim ilarw iresgo toterminals4 and 5; thesinglew ire goesto terminal3. 2. Ifthepotentiome terislabeled“density” turn tothelow position – iflabeled“sensitivity” turn to the high position. N otethispotentiome terhasa 270degreeturn. 3. A pplypow ertothe electronic m odule. 4. T urn theelectronic mo duleover. 756-601 SolitelVibratingRod LevelSwitch Terminals Voltage 3 and 4 4 to6 VDC 3 and 5 0.3to1.0VAC Figure 7 Front Rear
- Con necta digitalm ultim eterbetween pointsMP 5 on the backofthem oduleand ground connection (terminal3 on theelectronic m odule)orthe body ofthe vibrating probe. See F igure7on page7. 6. AdjustpotentiometerP2 on the rearofthe electronicmo d - uleto obtaina voltagebetw een0.4 voltsand 1.0 volts. T he reading shouldbe ascloseto 1.0 voltaspossible. 7. Gr asp the vibrating section ofthe sensorw ithyour hand. The vibration shouldstop and the relayw illchangestate. 8. Rem oveyour hand from the sensor. T he relayw ill changestate. 9. The electronic m oduleand probe arenow matched.
3.2 Agency Approvals
3.2.1 CS A
VXX -D1B X-XXX Class I,Div.2 Grou ps A,B,C ,& D C lass II ,Div.1 Grou ps E,F ,& G Type 4X
3.3 Replacement Parts
Item De scription PartN umb er
1 Base 004-9189-001
2 C over 004-9105-001
3 C overo-ring 012-210 1-345
4 Electronics m odule:
110 VAC Z30-9011-001
220 VAC Z30-9011-002
24 VD C Z30-9011-004
5 Bracket 005-668 0-001
6 Probe o-ring 012-240 8-001
7 Snap ring 010-513 8-001
8 Sleeve 004-0111-001
9 Probe Co nsultFactory
8 56-601 SolitelVibratingRod LevelSwitch These unitshave been testedtoEN 50081-2 and EN 50082-2 and areincompliancewith theEMC Directive89/336/EEC. These unitshave been evaluatedtothe applicableUL and CSA standards.CSA is accreditedas a NRTL (NationalRecognized TestingLaboratory)intheUnitedStates. NRTL/C
3.4 Specifications
3 .4.1 Performa nce De scription Specification Inputvoltage 110 VAC +10/-15%
220 VA C +10/15%
24 VD C (±10% )
Power consumption Lessthan orequalto3 VA Op eration frequency 350 Hz Ou tputrelay SPD T 8 amp @ 250 VA C SPD T 1 amp @ 24 VD C Tim e delay 6–10 seconds (depending on density adjustment) Processconnection 11⁄2" N PT Hou sing NE M A 4X Op erating processtemperature Standard -4°F to+230° F (-20°C to +110° C) Enhancedperform ance -40°F to+320° F (-40°C to +160° C) Am bientelectronicstemp. -40°F to+140° F , seechartatleft (-40°C to +60° C) Relativehumidity 98% Ma xim um processpressure 360 psig Ma terialsspecifications Vibrating rod 316 stainlesssteel Rigid extension 316 stainlesssteel Cab le for flexibleprobe Polyethelene coated steel Insertion length VXH 8.25 inches(209 mm ) VXR 10 to100 inches(25 to 254 cm) VXK 3 to65 feet(1 to 20 m eters) Ma ximu m mechanicalload on probe Stranded probe 63 Ft/lbs.(85 Nm ) Extended rigidprobe 63 Ft/lbs.(85 Nm ) Flexibleprobe 10,000 Poun ds(45 kN ) 956-601 SolitelVibratingRod LevelSwitch -40° F (-40° C) 0 0 -40° F (-40° C) 140° F (60° C) 95° F (35° C) 167° F (75° C) 320° F (160° C) Process Temp. Ambient Temp.
10 56-601 SolitelVibratingRod LevelSwitch Standard Length DIMEN SIONAL SPECIF IC ATION S inches(mm ) 1.73 (44) Dia. 6.34 (161) Insertion length 8.25 (209) 3.44 (87) Rotation clearance 11/2" NPT process connection 3/4" NPT Conduit connection 2.75 (69) 4.63 (117) Dia. 3.63 (92) 3/4" NPT plugged 1.5 (38) 3 .4.2 Physical Extended RigidProbe 1.73 (44) Dia 6.34 (161) Insertion length 11/2" NPT process connection 3.44 (87) Rotation clearance3/4" NPT Conduit connection 2.75 (69) 4.63 (117) Dia. 3.63 (92) 1.5 (38) 3/4" NPT plugged Extended Flexible Probe 1.73 (44) Dia. 6.34 (161) Insertion length 11/2" NPT process connection 3.44 (87) Rotation clearance3/4" NPT Conduit connection 2.75 (69) 4.63 (117) Dia. 3.63 (92) 3/4" NPT plugged 1.73 (44) Dia 1.5 (38)
3.5.2 SolitelLevelSw itch Extended FlexibleProbe
11 56-601 SolitelVibratingRod LevelSwitch
3.5 M odelNum bers
3.5.1 SolitelLevelSw itch Standard and Extended R igid Probe
1 Standard,length ininches
2 Enhanced performance*,lengthininches
3 Standard length incentimeters
4 Enhanced performance*,lengthincentimeters
H Standard rigid,8 .25" (21 cm) length R Extended rigid 0 110 VA C 1 22 0 VA C 2 24 VD C DE SIGN TYP E PROB E TYPE INPU T VOLTAGE D esigntypecode 1,2, 3,or 4 with probe typecode R: Code 000 fixedlengthof8.25" (21 cm) D esigntypecode 1 or 2 withprobe typecode R 10 to100 inches— Exam ple:10 inches= code 010 D esigntypecode 3 or 4 withprobe typecode R 25 to25 4 centimeters— Examp le:25 cm = code 025 INSERTIO N LEN GTH
3 Standard,length inm eters
D esigntypecode 1,3 to65 feet: Exam ple:10 feet= code 010 D esigntypecode 3,1 to20 m eters Exam ple:15 m eters= code 015 INS ER TION LENGTH *Recommended fortemperaturesup to+320° F(+160° C)or forstickymaterials.
BULLETIN: 56-601.6 EFFECTIVE: February2004 SU PERSEDE S: February2003 ServicePolicy Owne rsofMag netrolcontrolsm ay requestthereturn of a controlorany partofa controlforcom pleterebuilding orreplaceme nt.T hey willbe rebuiltorreplaced prompt - ly.Con trols returned under our servicepolicym ustbe returned by Prepaidtransportation. M agnetrolwillrepair or replace the controlat no costto the purchaser(or ow ner)otherthan transportationif: 1. Returned withinthe w arrantyperiod;and 2. T he factory inspection findsthe causeofthe claim tobe covered underthe w arranty. Ifthe troubleistheresultofconditions beyond our con - trol;or,isNOT coveredby the warranty, therew illbe charges for labor and the parts requiredto rebuildor replacetheequipment. In some cases itmay be expedient to ship replacement parts; or, in extreme casesa com pletenew control,to replace the originalequipment before itisreturned.If this is desired, notifythefactory ofboth themodel and serial numbe rs of the controlto be replaced. In such cases,creditforthem aterialsreturnedwillbe determined on the basisofthe applicability ofour w arranty. No claims form isapplication,labor,directorconsequen - tialdama ge willbe allowed. Return Ma terialProcedure So thatwe m ay efficientlyprocessany materialsthatare returned, it is essential that a “Return Material Authorization” (RM A ) num ber be obtained from the factory,priorto the m aterial'sreturn. T hisis available throughM agnetrol’slocalrepresentative orby contacting the factory.Pleasesupplythe following information: 1. Co mpan y Name 2. D escription ofM aterial 3. SerialNum ber 4. R eason forR eturn 5. A pplication An y unitthat w as used in a processm ust be properly cleaned inaccordance w ith O SHA standards,beforeitis returned to the factory. A M aterialSafetyData Sheet(MS DS ) m ustaccompany materialthatw asusedinany m edia. Allshipmentsreturned to the factorym ustbe by prepaid transportation. Allreplacem entsw illbe shipped F .O .B. factory. N OTE :See ElectrostaticD ischargeH andlingProcedure on page4 . ASS UR ED Q U ALITY& SER VICE COST LESS 5300 Belmont Road • Downers Grove, Illinois 60515-4499 • 630-969-4000 • Fax 630-969-9489 • www.magnetrol.
145 Jardin Drive, Units 1 & 2 • Concord, Ontario Canada L4K 1X7 • 905-738-9600 • Fax 905-738-1306
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